Methods of weaving carpets and rugs



Jan. 15, 1957 R. J. JACKSON METHODS OF WEAVING CARPETS ANb RUGS 2 Sheet s-Sheet 1 Original Filed Dec. 9, 1949 xxxxxxxxxxxx m xxxxxx xxx'xxx XOXXOXOXXXOX XXOXXOOXXXOX run (A l dberf J Jackson Pub! .4 fig:

R. J. JACKSON METHODS OF WEAVING CARPETS AND RUGS Jan. 15, 1957 2 Sheets-Sheet 2 Original Filed Dec. 9, 1949 XX+XXX+ XO+OXX+ XO+OXO+ OX+OOO+ OO+XOX+ XO+XXX+ XX+OXX+ OX+OXO+ OX+XOO+ OO+XOX+ XO+OXX+ XX+OXO+ hr 7 A la 5 A United States Patent-O METHODSOF AND'RUGS I Robert J. Jackson,,Hazardville,.Conn.,,assignor,by mesne assignments, to Bigelow-Sanford Carpetcompanmlnc, Thompsonville, Conn., a. corporation. of Delaware Original application December 9,. 1949,. Serial". No. 132,113, new Patent No.. 2,713,*877;..dalved.-July 26, 1955. Divided and this application May 2, 1955, Serial No. 505,320.

3 Claims. (Cl. 139-39) This invention relates. to methods of weaving fabrics having. fibrous, such as wool,.-pile'y.arn; particularly car'- pets' and rugs wovenonwire; looms;

A principal. object of this invention: isto;v produce on the surface'of the' fabric: weftwise: rows of uncutloops, in which rows there: are high: and." low.' pileloops, and weftwise rows of cut tufts, all of. which rows may be arranged'inwarpwise relation to eaclrtother'in any pattern: desired, such as. a pattern in which therows' of cut tuftsare interspersed with rows of loops;

An important feature of. this invention isthe employ ment in a wire loom of sets ofsw-ir'es consisting of wires of. evenheight and of wireshaving high and lowportions, i. e. cut-outv portions, some or all of" said wires having: blades at the outer endsthereof? and said 'wires being so placed and arranged as to produce the pattern of'loops and cuts tufts desired;

Other objects: and features will be more particularly pointed outin the appended claims'and will appear-from the following description taken in conjunctionwitlr the accompanying drawings in which:

Fig. 1- is a diagram of'a weave produced'witli a repeat set of four wires;

Fig. 2 is a diagrammatic planview. of therfabric resulting from the weaving operationofFig. 1;:

Fig. 3' is a plan view of a weavewith a: repeatof: seven wires;

Fig. 4 is. a partial elevation of an example Offfl: cut -out wire; and

Fig. 5 is a warpwise section of the weave.

Any known form of pile wire loom such as that described in. Patent No. 1,840,856,. may: be employed in the application of my invention.

A preferred weave, Fig. 5, of a common type consists of stutfer warps a, binder warps b, b, holding weft shot-s c above the stuffer warps and weft shots d held in position against the stutter warps by the binder warps. The pile warps A are strong enough to render, that is to be drawn, under a holding Weft shot without breaking when pulled by the high portion of a wire, as will be described.

The cut-out wires, Fig. 4, are formed with high and low portions according to the pattern of high and low warp loops desired. This wire has high portions, 1, 3, 5, 7, etc. and low portions between them. These high and low portions may be varied and located in the pile wire in accordance with the desired pattern and may be of any number, height and length. A cut-out wire may have a cutting blade C 'on its end. Each low portion is connected to the adjacent high portion lying outwardly thereof, that is, nearer the end of the wire which is withdrawn last, by a loop-raising portion or incline 7. These loop-raising portions are of the proper slope, not over 75 to raise the loops formed over the low portions of the wire to the height of the high portions as the wire is withdrawn.

The plain wires are of even height throughout and may or may not he provided with blades at their outer ends.

According to the method of weaving illustrated in Fig; 1, the first wire=ofa set isa plain wire l'll'of'even height which does not have a blade and" which on withdrawal forms a full complement of high loops X in the first row 11'. The second wire isa cut-out wire 20with a blade C at the end and when this wire is withdrawn, it lifts all the-warps and then cuts them to form a full complement of high cut tufts inthe second row 21'. At the same time it draws down the high pile loops X of the first row 11 wherever low loops were formed on the low portions of the second wire 20, and'therefor the first row 11 finally contains high and low loops X and 0 corresponding to the high and low portions of the second wire 20, as is shownin Fig. 2. The third wire 30' is a plain wire of uniform height and when this is withdrawn it forms a full complement of uniform high loops X in' the third row 31 and doe-s not effect any change in the cut tufts of row 21 as these tufts are not drawn down. The fourth wire 40' is a cut-out wire in which the high. and low portions differ from those in wire 20 so that the low loops created in row 31 by the withdrawal-of this fourth wire are positioned differently from those in row 11.

This completes the use of the set of four wires so that in thewoven fabric there is a pattern, as shown inEig. 2'; inwhi'ch' every other weftwise row has a full com.- plement of" cut tufts of a uniform height, corresponding to the high portions of the cut-out wires, and each of the other rows has a full complement of high and low loops indicatedas X andO. The cut tufts, being formed of cut high loops form a row which is higher than the loops in the other rows as shown in Fig. 5.

As above stated, the pile wool warps A are so strong that they are pulled successfully without breaking under the holding wefts which are drawn down against or close to thestuifc'rs. An effect of pulling the wool-pile yarns is that, as these yarns are pulled through the contracted opening between the holding weft shots and the stuflers, the surface of theyarns'is chafed as it is. pushed. back and the twist altered, that is, the yarn is. squeezed, between the holding weft shot and the stulfer andthe twist istliereby forced back in the loop so that the. amount of twist is concentrated in the shorter length of yarn formingthe low loop. As a result, the low loops appear on the surface of'the fabric in a rough, uneven and bunchy condition. The low loops, thus produced, have an appearance which is distinctly different from that of wool warp yarns woven in the usual manner over wires, without having their surfaces chafed or pushed back, which yarns have a comparatively smooth, even appearance.

Fig. 3 shows the pattern of a weave produced by a set of seven wires of which the first is a plain wire, the second is a cut-out wire without a cutting blade, the third is a cut-out wire with a cutting blade, the fourth is a plain wire, the fifth and sixth are cut-out wires without cutting blades and the seventh is a cut-out wire with a cutting blade. This produces two rows of high and low loops followed by a single row of cut tufts, then three rows of high and low loops, which may be diiferent from the first and second rows, and finally a row of cut tufts.

To weave several rows of cut tufts in succession the successive wires have cutting blades.

In order to produce a row of cut tufts of uniform height the next wire is a plain wire so that on its withdrawal none of the cut tufts is drawn down. But, if a cut-out wire is used in the row following the row of cut tufts, the high portions of the cut-out wire draw down and reduce the height of one leg of those out tufts, but that reduced leg would still be held in the bight of the weft and binder elements of the weave.

awmes The first wire of a set preferably should be a plain high wire. I

In cases in which the fabric is woven on a loom provided with the usual warp beam, the shapes of the wires in a repeat set to impart a given pattern are such-that every pile warp is of the same length as it passes over the high portions and the low portions of a set of wires. To secure this efiect the sums of the heights of the portions of a set of wires waipwise are the same. Thus, every pile warp is drawn evenly from the warp beam without variation in length.

Where the wires are used on a loom, such as a jacquard, provided with spools on which the pile warps are wound, the shapes of the wires are not so limited, because the drawofi. of the pile warps need not be the same.

The wires in a set, which may consist of plain wires Without a blade, or plain wires with a blade, cut-out wires without a blade and cut-out wires with a blade, may be arranged so as to produce a pattern of weftwise rows of cut pile, weftwise rows of high and low loops the loops being in any sequence, and the weftwise rows may be arranged in any desired relation with the novel result that the pile surface of this carpet has a striking diversity of weftwise rows arranged in novel patterns. Where, as in many cases, the high loops are cut to form cut tufts, such tufts are higher than the uncut loops.

The invention is applicable to weaving on a tapestry carpet loom and to weaving on a jacquard carpet loom in which the pile warps are selectively raised by the jacquard in accordance with a pattern.

This application is a division of my prior application Serial No. 132,113 filed December 9, 1949, now Patent No. 2,713,877.

I claim:

1. A process for'weaving in a wire loom a pile fabric floor covering having a warp pile face comprising some weftwise rows composed of high and low loops and other weftwise rows composed of cut tufts, said loops and tufts being woven into a backing structure including stufier warps, a series of holding wefts lying on one side of the stuffer warps, a series of non-holding wefts lying on the other side of the stufier warps and a binder warp looped about both series of wefts and holding the wefts under tension against the stuffer warps, said process comprising Weaving the pile warps over a set of wires, forming high and low loops on a cut-out wire with a blade prior to withdrawal, Withdrawing said wire and thereby converting said low loops to high loops and cutting all of the loops on said wire, forming loops of a uniform height on other .wires prior to withdrawal and thereby produc- .ing a floor covering .having a row of high and low loops,

a succeeding row of high. cut tufts and other rows of high and low loops.

2. A process for weaving in a wire loom a pile fabric floor covering having a warp pile face comprising some weftwise rows composed of high and low loops and other weftwise rows composed of cut tufts, said loops and tufts being woven into a backing structure including stuffer warps, a series of holding wefts lying on one side of the stuffer warps, a series of non-holding wefts lying on the other side of the stuifer warps and a binder warp looped about both series of wefts and holding the wefts under tension against the stutter warps, said process comprising weaving the pile warps over a set of wires, forming a row of high loops in a first row, reducing the height of some of those high loops by drawing them down according to the cut-out portions of the succeeding wire of the set, said succeeding wire being a cut-out wire with a blade, and at the same time forming with said succeeding wire a second row consisting of high cut tufts, and forming a third row, immediately following said second row, consisting of high and low loops according to the cutout portions of the wire next succeeding said third row.

3. A process for weaving in a wire loom a pile fabric floor covering having a warp pile face comprising some weftwise rows composed of high and low loops and other weftwise rows composed of cut tufts, said loops and tufts being woven into a backing structure including stuffer warps, a series of holding wefts lying on one side of the stutter warps, a series of non-holding wefts lying on the other side of the stufier warps and a binder warp looped about both series of wefts and holding the wefts under tension against the stutter warps, said process comprising weaving the pile warps over a set of wires at least some of which are cut-out wires with a blade, forming a row of high and low loops, forming the succeeding row of high cut tufts over such a cut-out wire, and forming subsequent rows of high and low loops.

References Cited in the file of this patent UNITED STATES PATENTS 2,164,090 Shuttleworth June 27, 1939 2,430,559 Dacey Nov. 11, 1947 2,477,248 Harding July 26, 1949 2,532,903 Groat Dec. 5, 1950 2,573,841 Groat Nov. 6, 1951 2,576,791 Jackson Nov. 27, 1951 FOREIGN PATENTS 36,870 Germany Sept. 16, 1886 

